Apparatus for molding material



July 14, 1936. E. D BoYLE APPARATUS Fox HOLDING MATERIAL Filed Aug. 9. 1933 2 Sheets-Sheet 1 1; 5. i l IF Y 24 Si .E l FTM" S 9" :zizi-'jfl "q "n H" l f f L/ -A 54 i |||ll|||||||l| MHH Hmmm im INVENTOR z BYEl/uwdag v A/ToRNx-:Y

July 14, 1936. lE. D. BOYLE 2,047,356

APPARATUS F'OR HOLDING MATERIAL Filed Aug. 9, 1935 2 Sheets-Sheet 2 L 22 M/@f 75 s man 1i www Minimum@ IWI e 'i L ORNEY Patented July 14, 1936 UNITED STATES PATENT, OFI-ICE 1 Claim.

This invention relates to means for and a method of molding granular mixtures, and more especially to an apparatus and method for molding a granular mix in a specially jolted mold.

It is well known that in the manufacture of cast stone from concrete mixes the density of the cast stone is not uniform even when wet pouring methods or methods involving Vibrating of the molds are resorted to in order to increase the density of the ilnished product.

'Ihe usual method of casting, namely, sand casting, is not adaptable to pneumatic ramming or even to hand ramming, as the soft sand mold gives or breaks at the slightest pressure. Furthermore, sand molds absorb considerable water from the outside or surface areas only, leaving the center of the mold in a highly liquid form. This again leads to a non-uniform casting. These defects are not noticeable at iirst, but upon exposure to varying weather conditions, cracks and other defects caused by strains in the cast appear in the product. Even the use of a semi-dry mix, which is the best mix because of the small amount of Water present, does not alleviate conditions, unless it is used together with apparatus of the kind herein described and together with the method herein described.

Furthermore, if a wet mix is used such as is commonly used in the sand casting of concrete blocks, no considerable pressure can be applied to further compress the concrete block after the surplus water is absorbed by the sand mold, thus leaving onlyA the necessary water for the crystallization of the cement and leaving the mass in a honeycombed condition. If it were possible at this time to apply pressure, then we would have a dense uniform mass. But it is impossible to do this in a sand mold. With the apparatus de- `scribed below, this is possible because of the rigid porous mold and the combined pressure and jolting used. It is well known that the absorption o1' the water of crystallization leaves minute voids or air pockets in the cast block. Flnthermore, the casting of a highly liquid or wet mix has been found to produce a very weak product because of the originally weak or unsaturated solution of cement used.

Applicants method and means for producing molds of granular mixtures utilizes a rigid metal mold having holes drilled therein, the mold being metal but lined with a iine wire screen meshwork upon which is spread a heavy canvas cloth into which the semi-dry mix is poured. In order to increase the density of the concrete mix a horlzontal `Jolting action is used together with the vertical application of a very high pressure. The vertical application of pressure serves to squeeze 01T all the excess water and air while the canvas lining retains the mix in the mold, and when pressure is released from the mold there is no elasticity of compressed imprisoned air or water to cause the solid mass to distort from its already compressed condition.

The mold is iirst filled with the right quantity of material, the quantity being determined by 10 Weight or measure so that the unit, when pressed to the required density, will be the required size. Next, the hydraulic member is put in place above the mix and the Water or oil under very high pressure is admitted to the cylinders of the hy- 15 draulic press. Simultaneously, the mold is jolted by a special pneumatic cylinder and piston member and this jolting is continued until there is no further increase in the density of the mix and the excess Water has been completely expelled. The 20 operation of the combined pressure, jolting and removal of excess water produces an extremely condensed mix in which practically all of the air and excess water is displaced from between the particles of the cement mix. 25

The resultant increased density of the product greatly improves the capacity of the cast mix to withstand various destructive influences of weather. wear and tear, pressure and the like, to which it may be subjected in service. For pur- 30 poses of comparison, it has been found that the product made in accordance with my method and apparatus withstands strains two to three times as great as those of the ordinary sand cast product. 35

One modification of means for carrying out the above described method of casting the concrete or cement mix is disclosed in the drawings made a part of this description. In these drawings, corresponding parts are similarly numbered in all the drawings.

In the drawings, Figure 1 is a sectional view of a pneumatic device embodying my invention. and taken along the line I--I of Figure 3.

Figure 2 is a horizontal top plan view of the same device taken on the line 2-2 of Figure 1.

Figure 3 is a sectional view of the device shown in Figure 1 taken along the line 3 3.

Figure 4 is a view somewhat similar to that of Figure 1, but showing the cylinders in plan View and the mold with its concrete or cement mix in cross-sectional view taken along the line 4 4 of Figure 3. Figure 5 is a detailed cross-sectional view of the die plates showing the suspending means 82 55 and the rollers 88 between the plates 80 and 8|. Figure 6 is an enlarged detailed sectional view of the right hand corner of the mold 90 shown in its entirety in Figure 4.

Referring now, more particularly to the embodiments shown in the respective ilgures. the device comprises girders or I-beams I8, 2|, 22, 23, and 3|, 32, 33, the last six of which are arranged in the form of two inverted U frames, all the girders being held together by cross members 48, 50. 5|, 52, 53, 54, 58 and all being strengthened by pairs of struts 4, I5, 24, 25, 34, 35.respectively. The U frames are in turn attached to base plate 60 thereby being formed into an extremely rigid framework for the pneumatic pressing mechanism described below.

'I'he cylinders 13 and 14 of the pneumatic vpressing mechanism are also very rigidly mounted and bolted in a slidable framework made up of channel irons 6| to 58, members `8| to 54 of which are somewhat longer than members to 88 and are slidably supported by cross members 45, 50, 55 and 56 respectively. Cross pieces 63 to 12 are used to join the channel irons 5| to 58 together as well as to rigidly support the cylinders 13 and 14. Highly compressed air, or water or oil under very high pressure is admitted to the cylinders 13 and 14 through pipe 15. 'I'he compressed air causes cylinders to become illed with air under pressure and the pistons 16, 11 to be forced downward which in turn causes the connecting rods 18, 19 to force the plate 80 and its slidably associated die plate 8| down upon the concrete or cement mix 85 in the mold 90. Die plate 8| may be movably mounted on the plate by means of the suspension provided by angle iron and 82 and rollers 83 held in grooves between plates 80 and 8|. Mold 90 may be similarly slidably mounted on base plate 60 by means of rollers 84.

The vibrator |00, has a casing ilxedly mounted to the base 60 and is operated on the principle common to all vibrators, namely, of supplying air or steam to the casing and controlling the entrance and exit port for the air or steam by means of a reciprocating piston. Such types of vibrators are well known in the art, and it is therefore believed unnecessary to enter into a detailed description of the control for the vibrator.

'Ihe obvious operation that it is necessary for the vibrator to impart is a very rapid succession, or a series of blows or jolts to the mold 90. This vibration is in turn imparted to the cement mix which is thereby caused to become more dense and more solidified.

For the purpose of explaining why this product is much stronger than the product cast in the ordinary and customary manner now used, the following line of reasoning may be advanced,

although the validity of the reasons in no way is to ail'ect the invention. The horizontal jolting, combined with the vertical pressure causes laminations of the article perpendicular to the direction of greatest pressure. notwithstanding, is greatly improved by being made with my apparatus and in accordance with my method.

The mold 90 as well as the die plate 8| has a number of peri'orations 8| in the walls and sides thereof. These perforations, if left uncovered, would allow the cement mix to pass through. To overcome this, the mold 00 is lined, rst with a wire screen 82 (Figure 6) over which in turn is placed a canvas lining or bag 93 into which the cement mix is poured.

In order to operate this apparatus, the pneumatic pressing mechanism is slid back so that the plates 80 and 8| leave the mold open at the top. The wet or semi-dry mix is then poured into the mold which' is lined with the wire screen canvas material.

Then the pneumatic pressing mechanism is slid back to a position such that die plate 8| is directly over the opening in the mold. The wire mesh canvas material, if not already in the place on the lower side of the die plate 8|, is spread over the cement mix with the canvas side in contact with the cement mix. Compressed air is then admitted to the cylinders 13 and 14 and the pressure is increased. In the meantime, the die plate 8| is inserted into the upper opening of the mold 90 and the vibrator |00 is switched into operation causing a jarring of the mold 90.

The article produced, 5

This combined jarring and pressure is continued 35 as above described until the mix is consolidated and solidified.

Although the above description has been given with more particularlty to cement mixes, it may, obviously, be applied to the consolidation of other 4 mixes, such as tar, abrasives, carbon, glue, etc., mixes.

What is claimed is:

In a machine for molding a cement mix, the combination of a'base plate, an inverted vertical 4 U-shaped frame having arms between which the base plate is iixed, a mold slidably mounted on the base plate, additional means comprising a reciprocating air hammer for shaking the mould horizontally, a die for compressing the cement mix in the mold, and a hydraulic compression member having its cylinder walls restrained by` the base of said U-shaped frame and its piston slidably pressed against said die, whereby a constant vertical pressure is exerted on the mold which is at the same time moved in a plane perpendicular to the vertical pressure, said mold having openings porous to air and water in the cement mix.

EDWARD D. BOYLE. 

